Automated container bulking system and method optionally integrated with automated dispensing system and/or automated labeling and packaging system

ABSTRACT

An automated system and method for emptying the contents of pharmaceutical containers. In an embodiment, a gripper unit receives and holds a pharmaceutical container. A cutter cuts the pharmaceutical container, and a rotating unit, operable with the gripper, rotates at least a portion of the gripper unit to empty the contents of the pharmaceutical container.

RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 12/463,776, filed May 11, 2009, now U.S. Pat. No. 8,117,809, whichis a divisional application of U.S. application Ser. No. 10/634,992,filed Aug. 6, 2003, now U.S. Pat. No. 7,530,211, which claims priorityto, and is a continuation-in-part of U.S. application Ser. No.10/215,249, filed Aug. 9, 2002, now U.S. Pat. No. 6,892,512 which claimspriority from U.S. provisional application Ser. No. 60/401,340 filedAug. 7, 2002, all of the above applications are incorporated herein byreference in their entirety.

FIELD OF THE INVENTION

The present invention generally relates to systems and methods foremptying the contents of pharmaceutical containers, includingmedications, into a container to facilitate the automated and/or manualdispensing of pharmaceuticals. The present invention also generallyrelates to systems and methods for automatically combiningpharmaceuticals and/or medications for later dispensing and/or packagingof pharmaceuticals, medications, prescriptions and/or prescriptionorders, automatically and/or manually. The present invention may be usedfor mail order pharmacies, wholesalers and/or central fill dealers forsubsequent distribution or sale including a retailer.

BACKGROUND OF THE INVENTION

In mail service pharmacies and large retail pharmacies, prescriptiondrugs are dispensed in a high volume. For such services, it is known touse an automatic pill dispensing system to carry out the dispensing ofthe prescription drugs automatically at a rapid rate and to label pillcontainers which can then be provided to the patient for whom theprescriptions were written.

A known automatic pill dispensing system is described in U.S. Pat. No.5,771,657 issued to Lasher et al., which is incorporated herein byreference. In the patent, as shown in the schematic illustration of FIG.1A, orders (e.g., orders to fill prescriptions) are received by a hostcomputer 9 which forwards the orders to a distributed computer systemincluding a central computer called Pharmacy Automation Controller 10(PAC). PAC 10 maintains an order file of the information about eachprescription to be filled in an order including all of the informationneeded to fill each prescription, and prepares a prescription label foreach prescription and the information to print literature to go in ashipping container with the prescription or prescriptions. PAC updatesthe order file to maintain a record of the current status of eachprescription being filled as it progresses through the automated system.

PAC 10 controls a set of Print, Apply and Load (PAL) stations 14 whichprint prescription bottle labels, apply the prescriptions toprescription bottles, and load the labeled bottles onto bottle carriersthat preferably receive the bottles in scheduled locations. PAC 10 alsocontrols a carrier conveyer system 21 that carries the bottle carriersto different parts of the system, and one or more automatic drugdispensing machines 23 that dispense tablets and/or capsules into theprescription bottles in the bottle carriers as they are carried by theconveyer system 21. PAC 10 also controls bottle cappers 25 that applycaps to the bottles, and one or more OCP stations 29 that unload bottlesfrom the carriers and place them in the shipping containerscorresponding to the patient orders.

PAC 10 also controls literature printers 31 which print literature foreach prescription order and enclose the literature for each prescriptionorder in an envelope, print a bar code that shows through a window inthe envelope identifying the prescription order, and then place eachenvelope on a literature conveyer 34 which carries the envelope from theliterature printers 31 to the OCP stations 29.

The conveyer system 21 carries the bottles in the carriers from the PALstations through the automatic drug dispensing machines 23 to the bottlecappers 25 and then from the bottle cappers to the OCP stations 29. Theconveyer system 21 also carries the empty carriers back to the PALstations 14. From the bottle cappers 25, the conveyers 56 feed thecarriers onto an endless conveyer loop 71 which will transport the fourcarriers of a rank to one of six OCP stations 29.

The OCP stations each also have a literature dispensing mechanism, whichinserts printed literature into each shipping container with the filledand capped prescription bottles.

As shown in FIG. 1B, bottles to be automatically filled with theprescription drugs are introduced to the automated system by hoppers 37,which receive the bottles in bulk form and automatically feed thebottles to unscramblers 39. One of the hoppers 37 and one of theunscramblers 39 will be for large bottles (e.g., 160 cc), and theremaining hoppers and unscramblers will be for small bottles (e.g., 110cc). The small bottle size can preferably accommodate a majority of theautomatically filled prescriptions. In the unscramblers, the bottles aresingulated and oriented so that the bottle opening first faces downward.The bottles are then righted and directed to PAL stations 14 on bottleconveyers 41 and 43, one for large bottles and one for small bottles.

As shown in FIG. 1B, the conveyers 45, under control by PAC, carry thebottle carriers from the four PAL stations 14 to carrier buffers at theentrances of the four automatic drug dispensing machines 23 in which thetablets or capsules of the prescriptions are automatically dispensedinto the prescription bottles under the control of PAC 10. Because ofthe organization provided by the carriers, the bottles are arranged intofour columns approaching each automatic dispensing machine 23. Sincethere are four automatic dispensing machines 23, 16 parallelprescription bottle columns approach the dispensing machines. In thespecific embodiment of the invention, the four automatic drug dispensingmachines each have 384 drug dispensers arranged four columns wide and 96rows deep to provide a total of 1,536 pill dispensers. The automaticdrug dispensing machines are similar to those described in the U.S. Pat.No. 5,660,305, which is hereby incorporated by reference. Eachdispensing lane is divided into 32 buffer assemblies each containingtwelve drug dispensers oriented six on each side of a conveyer withinthe dispensing machine.

The carrier will be released by the PAL station 14 onto a conveyer 45which carries the carrier loaded with the labeled empty prescriptionbottles to an automatic dispensing machine 23, of which there are four,one for each PAL station 14. When a carrier moves out of the last rowposition in a dispensing machine, all of the prescription bottles inthat bottle carrier should be filled and a conveyer 56 transports theprescription bottles now filled with the prescriptions to a bottlecapper 25.

The bottle quality assurance area 109 has several stations at whichpharmacists will scan the bar code on the bottles and visually inspectthe contents of the bottles. The scan of the bottle bar code will bringup a display on the pharmacist's terminal which includes all theinformation regarding the particular prescription and order includingthe drug name, and instructions which identify the reason for theverification. All of the bottles that pass this inspection are insertedby the pharmacist on a bottle stream conveyer 111 to send the inspectedbottles to the BSP station 112. The conveyer 108 leads to a star wheeldiverter mechanism 114 which under the control of a controller for theBSP station deposits the bottle in a bottle stream conveyer 116 leadingto the bottle quality assurance area 109 or into a bottle streamconveyer 118 leading to BSP station 112.

If the literature pack is on the conveyer 34, but because of failure ofthe bar code reader (not shown) or the literature sorting mechanism,does not get diverted at station 112, the conveyer 34 will carry theliterature package to the package quality assurance area where it can bemanually added to the package. If, because of a malfunction, aliterature envelope is not deflected by a deflector (not shown), becauseof, for example, an improper bar code on the envelope, the envelope willcontinue on the conveyer 34 to the end of the conveyer and be dumpedinto a receptacle at the package quality assurance station 96. If thebag does not contain a literature pack, then the bag is diverted into atote (not shown) which will then be transported by a conveyer 101 to thepackage quality assurance station 96 where the shipping container willbe assembled with the literature pack manually 137. FIG. 2 shows anotherknown dispensing system as described in U.S. patent application Ser. No.10/215,249, which is incorporated herein by reference. In particular,FIG. 2 shows a system 250 that can include a storage device for packages203, dispenser for the packages 205, storage device for bottles filledwith counted pills 209, dispenser for the bottled with counted pills207, storage device for patient specific literatures 211, dispenser forthe patient specific literatures 213, consolidation station 215, andhost computer 201. System 250 can be referred to as a automated labelingand packaging system (ALPS).

The system shown in FIG. 2 can also include one or more local computers(not shown). For instance, each of the components (e.g., 203, 205, 209,207, 211 and 213) can be connected to one or more local computers. Thelocal computers in turn are connected to host computer 201. In this way,host computer 201 and local computers are configured to control thevarious components of the present invention.

A local computer can also function with a standard Programmable LogicController (PLC). A PLC typically includes an I/O card to turn on/off adevice. Accordingly, when a component is to be controlled by turning iton/off, a PLC can be used. When a large quantity of data is to beexchanged, a local computer can be used.

Host computer 201 can receive a request to fill an order, optionally incombination with the local computer(s) and/or the various components. Inresponse, host computer 201 creates an order number and determineswhether the order contains an order that requires bottles to be filledby counting individual tablets and whether the order contains an orderthat requires packages from the storage device for bottles 209.

The storage device for packages 203 stores packages that containpharmaceutical products. For example, one set of packages may contain apredetermined number of tablets (e.g., 500 tablets) of a certain drug(e.g., Allegra). Another set of example packages may include liquidpharmaceutical products. The packages can be made by original producersof drugs (e.g., Hoechst Marion Roussel). The packages can also be bulkbottles that are filled by any one of many automated (e.g., the ADDS) ormanual methods known in the art. These packages can then be shelved sothat their locations can be automatically identified. In turn, thedispenser for the packages 205 is configured to automatically identifythe location of any package with a certain type of drug, dosage and/orquantity and configured to pick one or more packages from the identifiedlocation. In other words, a package contains a pharmaceutical productwithout having been pre-designated for any specific order when thepackage was created.

In operation, the command to locate and pick one or more packages isreceived from host computer 201. The dispenser for packages can also beconnected to its own local computer to perform the necessary functionsto locate and pick one or more packages in accordance with the commandfrom host computer 201. It should be noted that the packages stored inthe storage device for packages 203 are not designated for any specificpatient. In other words, any package can be picked to fill an order of apatient as long as the type of drug, dosage and/or quantity are matchedwith the order.

FIG. 2 can also include a standard sensor or a standard counter toindicate when a specific type of package is out of stock in the storagedevice for packages 203. These sensors or counters can be present ateach location (or a substantial number of them). The signals from thesensors or counters can be communicated to, for example, the hostcomputer 201 via the local computer. In turn, the host computer 201 cannotify an operator or system to replenish the specific packages and/orstop the process of filling orders that require the specific type ofpackage that are out of stock in the storage device for packages 203. Inaddition, or optionally, host computer 201 can send a query to thestorage device for packages 203 regarding whether a certain number ofcertain packages are available to be dispensed. In response, the storagedevice for packages 203, or in combination with its local computer, cansend a response based on information from the sensors and/or counters.Alternatively, sensors may be placed on the robot arm or picking deviceto provide the similar functionality. In yet another alternative,sensors are not utilized and the system keeps logical control by knowinghow many packages have been placed in a channel and how many packageshave been removed from the channel.

The dispenser for bottles 207 is configured to receive bottles thatcontain specific number (e.g., 1-500 or more) of pills for a specificorder. For example, one bottle may include 350 tablets of one type ofdrug for patient A, while another bottle may include 600 tablets ofanother type of drug for patient B. The bottles can be filled by anyautomatic dispensing mechanisms known in the art (e.g., the system shownin U.S. Pat. No. 5,771,657). Bottles can also be manually filled (by,e.g., a pharmacist).

If an automatic dispensing system is used, host computer 201 sendscommands to fill bottles with certain number of pills for a certain typeof drug. Once they are filled, the bottles are stored in the storagedevice for bottles 209. In a similar fashion, in a manual system, thedispensing person would receive an instruction to count certain numberof tablets for a certain type of drug. The person fills bottlesaccording to the instructions and forwards the bottles to the storagedevice for bottles 209.

Once the storage device for bottles 209 receives all the bottlesnecessary to fill an order, the storage device for bottles 209 or inconnection with its local computer sends a message to the host computer201 indicating that the bottle portion of the order has been filled. Forexample, an order to fill an order may require 1450 pills of a certaintype of drug. In this example, the storage device for packages 203 mayalready have two packages each with 500 pills of the drug. If so, onebottle with 450 pills of the drug is necessary to fill the bottleportion of the order. (If one bottle cannot receive all 450 pills thenmore than one bottle would become necessary to provide the 450 pills).

The storage device for literature packs 211 contains literatures to bepackaged with specific orders. For example, a set of literature packsfor one order may include information relating to each of the prescribeddrugs, how often each drug must be taken, billing information, specialinstructions from the prescribing doctor, insurance information,refilling information and/or general information, for example health ornotification of other services. The set of literature packs is thenpackaged per order and collected in the storage device for literaturepacks 211. Once the necessary literature packs are created, the storagedevice for literature packs 211, or in combination with its localcomputer, can notify the host computer 201 that the literature pack hasbeen printed.

Upon receiving various information from the storage device for packages203, storage device for bottles 209 and storage device for literaturepacks 211, host computer 201 then sends instructions to the dispenserfor the packages 205, dispenser for bottles 207 and dispenser forliterature packs 213, or to their local computers, to dispense necessarybottle(s), package(s) and literature pack(s) to fill one or more orders.The dispensed bottle(s), package(s) and literature pack(s) are thenconsolidated by the consolidation station 215 and then sent, distributedor mailed out directly or indirectly to patients associated with theorders.

FIG. 3 shows yet another known system as disclosed in U.S. Pat. No.5,208,762 to Charhut et al., which is incorporated herein by reference.As illustrated in FIG. 3, a system 310 is provided for dispensingprescriptions. The system 310 includes three lines 312, 314 and 316 ofmachines that can automatically fill, label, cap, and sort vials 318 inaccordance with a patient's prescription order under the control of anappropriate control system.

For ease of understanding, only one of lines 312, 314, and 316 will bedescribed in detail. However, with the exception of vial size, thedescription is applicable to each of lines 312, 314, and 316. Therefore,reference numerals identifying items in the drawings which havecounterparts associated with each line will be used generically in thisdescription, but in the drawings will carry additional designations suchas a, b, and c to identify those items corresponding to the particularlines.

The first machine position at each line of the system is a vialunscrambler 320. In such a machine, vials of one size are dumped into ahopper 322 in bulk form.

The unscrambler 320 orients the vials upright in a separator 323 andspaces them on a conveyor 324 ready to feed into a vial filler 326. Theunscrambler 320 can also be equipped to shoot a blast of air into thevial, cleaning debris that might be present.

From the unscrambler 320, a vial will travel via the conveyor 324 to thevial filler 326 (also referred to as the filler). The vial filler 326preferably comprises a modified Automatic Tablet Control (ATC) machine.The ATC machine is capable of holding up to about 480 different oral,solid medications. Such medications are held in canisters calibratedspecifically for those drugs. There can be one or more ATC machines perline depending on drug mix and drug volume required by the institutionin which the system 310 is installed.

The conveyor 324 brings the vial under a filling position of the filler326 and a signal from the controller system activates the appropriatedrug canister, as required. More than one canister can be assigned to aspecific drug and can dispense doses simultaneously. The drug doses arecounted into the vial until filling is complete.

After filling, the vial is labeled by a label machine 328 (also referredto as the labeler). The labeler 328 can be located downstream of thevial filler 326 as shown or it can preferably be located under the vialfiller 326 to label vials during or immediately following filling. Asignal from the control system is sent to the label machine 328 at thesame time the vial is being filled. The label machine print humanreadable information, as well as bar code information on demand. Thelabel information is kept in a data base and contains drug description,as well as any warning statements.

After the label is printed, a reader can be provided associated with thelabeler 328, to verify the contents of the label by reading the printedbar code. Once a vial is filled and labeled, it travels down theconveyor 324 to a capping machine 330 (also referred to as the capper).The capping machine 330 grasps the vial and preferably applies achild-resistant cap 331 to the vial.

Just after the capper 330, each line includes a bar code reader 336 anda wrap belt 339 disposed on opposite sides of the conveyor 324. The wrapbelt 339 serves to spin a vial around so that the bar code thereon canbe read by the reader 336. The bar code reader 336 verifies thelegibility of the bar code on the label and confirms the prescriptionnumber to the control system.

After the vial is capped, a sensor associated therewith verifies thatthe cap has been properly applied. The capper 330 preferably includes areservoir 333 that is sufficiently large to store one full shift'ssupply of caps.

Once a vial has been capped and the contents are verified by the cappersensor 336, it proceeds to an accumulator or accumulation station 332positioned at the end of its respective conveyor 324. The accumulationstation 332 serves two functions: sorting and ejecting. Vials areejected when they have an improper drug count, unreadable labels, orimproperly seated caps. A signal sent by the filler 326, labeler 328, orcapper 330 causes a defective vial to be ejected into a reject bin 335by a blast of pneumatic air gun 334 if any of the situations isdetected. When a vial is ejected, the control system places a refillrequest with the filler 326 on a priority basis so that another attemptis made to complete the prescription order.

A circulating conveyor 342 (also referred to as a sorting conveyor)carries circulating bins 340 along a path that brings each of the binsunder an accumulator 332 once per rotation. The bins 340 are bar codedand the control system assigns at least one circulating bin 340 perpatient. If a particular patient has more vials than a single bin canhold, a second or third bin will also be assigned. A bin 340 willcirculate on the conveyor 342 until a patient's total order has beencollected. The bar code on the bin 340 will be read by bar code reader363 prior to travel under the accumulators 332 and a signal willcorrectly time an accumulator 332 to discharge a specific patient's vialinto the bin 340.

All properly bottled vials are assigned to a location on the accumulator332 where they await a circulating bin 340 in which they are to beplaced. These locations are also referred to as the staging output area.The accumulator 332 preferably has up to twenty locations for temporaryvial storage.

The accumulators 332 are positioned above the conveyor 342 so that thevials awaiting on an accumulator can be placed into a passing bin 340.To this end, each accumulator 332 has associated therewith a pneumaticgripper 337 on a rodless cylinder for placing upon command, a vial intoan accumulator position.

One or more of the bins is assigned to a patient by the control system.As the assigned circulating bin(s) 340 move(s) under the vialaccumulator 332, the accumulator 332 drops the vials into the assignedbin(s). The drop of the vials is effectuated by means of a release doorcontained in the accumulator position on which the vials rest and whichis activated by a solenoid controlled by the control system. Preferably,the accumulator 332 is capable of placing its entire contents in onebin, if necessary. In this manner, all of the vials for one patient'sorder can be sorted and placed together in a bin.

When a patient's total order has been accumulated in one or more bin(s)340, the sorting conveyor 242 transfers the bin(s) 340 to one of aplurality of spurs.

Spur 350 is a conveyor referred to as the exception conveyor. An orderis placed on spur 350 if, for some reason, the contents must be modifieddue to error. Spur 350 can also be used to place medications other thanoral solids into a patient's bin 340. This spur 350 can carry a bin 340under a rack that contains, for example, liquids or creams. By readingthe bar code on the bin 340, the rack automatically would discharge thecorrect medication into the bin 340.

Spur 352 is a conveyor referred to as the mail order conveyor. An orderis placed on spur 352 if it is to be mailed to a patient. Spur 354 is aconveyor referred to as the pick-up conveyor. An order is placed on spur354 if it is to be picked up by a patient, e.g. a walk-in.

As illustrated, a variety of extractors are operatively positioned tomove bins onto and off of the conveyors 342, 350, 352, 360, and 361.These extractions are generally designated by the numeral 362. Extractor362 a, upon command, diverts bins from conveyor 342 into conveyor 350.Extractor 362 b, upon command, diverts bins from conveyor 342 ontoconveyor 352. Extractor 362 c, upon command, diverts bins from conveyor342 onto conveyor 354. Extractor 362 d, upon command, diverts returnedbins from conveyor 361 onto conveyor 360. Extractor 362 e, upon command,diverts returned bins from conveyor 360 onto conveyor 342. Additionally,a scanner 363 is provided that reads bar codes on returned bins.

An empty bin 340 is placed on return conveyor 360 or 361 which places itback on circulating conveyor 342. Return conveyor 360 is used to returnbins used for mail orders, while return conveyor 361 is used to returnbins used for pick-up orders. At the point of return, the bar code onthe bin (340) will be read and noted in the control system as anavailable bin. If the bar code is unreadable, the bin 340 isautomatically ejected from the system 310. The return is located justdownstream from the take-off on the circulating bin conveyor 342 so thecirculating conveyor 342 will always be full. Overhead transfercylinders 364 are used to transfer bins 340 from one straight conveyor342 a to another straight conveyor 342 b, which together form thecirculating conveyor 342.

In the above described conventional systems, in order to automaticallyand/or manually dispense medications and/or pharmaceuticals, the systemmust obtain large numbers of medications and/or pharmaceuticals from avariety of manufacturers using a variety of different stored bottlesand/or packaging. The conventional systems shown in FIGS. 1-3 do notutilize, contemplate or suggest the use of a system that can automatethe process of emptying the contents of manufacturers' drug carryingcontainers into a receptacle having a larger capacity, therebysimplifying the number and types of bottles that must be used fordispending pharmaceuticals.

SUMMARY OF THE INVENTION

Computer-assisted methods, systems and mediums of the present inventionovercome, among others, the shortcomings of the above-describedconventional systems.

In one embodiment, an automated system is provided for emptying contentsof pharmaceutical containers, including medications. The system includesa gripper unit for receiving and holding a pharmaceutical container, acutter for cutting the pharmaceutical container, and a rotating unitoperable with the gripper unit that rotates at least a portion of thegripper unit to empty the contents of the pharmaceutical container,optionally into a bulk-up container. The pharmaceutical container can beof different shapes and sizes. The bulk-up container can comprise asubstantially uniform sized container to facilitate the automateddispensing of the medications. The gripper unit can include first andsecond, optionally V-shaped, interlocking fingers.

The system can also include a robot for placing the pharmaceuticalcontainer in the gripper unit. A conveyor can also be provided thattransports the pharmaceutical container in proximity to said robot.

In addition, a vision system can be utilized by the robot to facilitatedetermining the position of the pharmaceutical container on theconveyor. When the vision system does not recognize at least one of thesize and shape of a pharmaceutical container, the pharmaceuticalcontainer is transported off the conveyor, optionally into a bin.

The cutter can be an ultrasonic cutter, with a blade that optionallymoves in a direction substantially parallel to a belt of the conveyor. Arodless air cylinder is used to facilitate movement of the cutter.

The system can also include an arm that rotates to a first position toreceive the cut portion of the pharmaceutical container. The arm canalso rotate to a second position to facilitate placing the cut portionin a waste repository. The arm can include or utilize a vacuum thatretains the cut portion of the pharmaceutical bottle when the arm is inthe first position. The vacuum can decrease when the arm is in thesecond position to effect release of the cut portion into a scrap bin.

The system can also include a scrap chute that receives a portion of thepharmaceutical container subsequent to emptying the contents of thepharmaceutical container. The scrap chute can be in a distal positionwith respect to the gripper unit prior to emptying the contents of thepharmaceutical container. The gripper unit can move to a proximalposition with respect to the gripper unit to receive the portion of thepharmaceutical container held by the gripper unit subsequent to emptyingthe contents of the pharmaceutical container. The scrap chute can returnto the distal position to place the portion of the pharmaceuticalcontainer held by the gripper unit in a scrap bin.

The system can also include and/or utilize a sensor system to determinewhen the contents of the pharmaceutical container are no longer beingemptied. In an embodiment, the sensor system can include a light emitterand a light receiver so that the light emitter provides a light beamthat is broken by the contents of the pharmaceutical container when thecontents of the pharmaceutical container are being emptied.

The system can also include a detection system to detect when thepharmaceutical container is no longer being held by the gripper unit.The detection system can include a light beam source and reflector, suchthat the reflector does not sense the light from the light beam sourcewhen the pharmaceutical container is held by the gripper unit.

A method for empting the contents of pharmaceutical containers is alsoprovided. In an embodiment, the method includes the steps of holding apharmaceutical container for cutting, cutting the pharmaceuticalcontainer, and rotating the pharmaceutical container to empty thecontents of the pharmaceutical container.

The method can also include the step of placing the pharmaceuticalcontainer in a waste repository subsequent to cutting. The method canalso include the step of electronically viewing the pharmaceuticalcontainer prior to the holding and cutting steps. The viewing canprovide position information of said pharmaceutical container.

The method can also include the step detecting when the contents of thepharmaceutical container are no longer being emptied. The method canalso include the step of detecting when the pharmaceutical container isno longer being held.

In an embodiment, the system comprises means for receiving and holding apharmaceutical container, means for cutting the pharmaceuticalcontainer, and means for rotating at least a portion of said the forreceiving and holding to empty the contents of the pharmaceuticalcontainer. The system can also include means for placing thepharmaceutical container in the means for receiving and holding. Inaddition, the system can include means for transporting thepharmaceutical containers in proximity to the means for receiving andholding.

The system can also include means for viewing and determining theposition of the pharmaceutical containers on the means for transporting.In addition, the system can include an arm that rotates to a firstposition to receive the cut portion of the pharmaceutical container, anda second position to place the cut portion in a waste repository.

The system can also include means for determining when the contents ofthe pharmaceutical container are no longer being emptied, as well asmeans for detecting when the pharmaceutical container is no longer beingheld by the means for receiving and holding.

In another embodiment of the present invention, an automated system foremptying the contents of pharmaceutical containers can include a gripperunit for receiving and holding a pharmaceutical container, a cutter forcutting the pharmaceutical container, and a control system forcontrolling the operation of the gripper unit and the cutter. The systemcan further include a rotating unit, operable with the gripper and thecontrol system, that rotates at least a portion of the gripper unit toempty the contents of the pharmaceutical container.

The control system can include a keyboard, control logic, a display, anda processing unit. The control system can receive identificationinformation of an operator of the system. The system can also include anindicia reader that interfaces with the control system. An indiciaassociated with a pharmaceutical container can be read by the indiciareader, and the control system can determine whether the pharmaceuticalsare authorized.

The system can further include a robot that optionally interfaces withthe control system, for placing the pharmaceutical container in thegripper unit. A vision system can be utilized by the robot, andoptionally interface with the control system to determine, for example,the position of the pharmaceutical containers. The contents of thepharmaceutical containers can optionally be emptied into one or morebulk-up containers.

The system can also include an arm that optionally interfaces with thecontrol system. The arm can rotate to a first position to receive a cutportion of the pharmaceutical container, and also rotate to a secondposition to place the cut portion in a waste repository. The arm canoptionally utilize a vacuum that retains the cut portion of thepharmaceutical bottle when the arm is in the first position, and thevacuum can be reduced when the arm is in the second position to effectrelease of the cut portion.

The system can also include a scrap chute, optionally controlled by thecontrol system, that receives a portion of the pharmaceutical containersubsequent to emptying the contents of the pharmaceutical container. Thesystem can also include a sensor system, optionally interfacing with thecontrol system, to determine when the contents of the pharmaceuticalcontainer are no longer being emptied. The system can also include adetection system, optionally interfacing with the control system, todetect when the pharmaceutical container is no longer being held by thegripper unit.

In another embodiment of the present invention, a prescription fillingand packing system can include a gripper unit for receiving and holdinga pharmaceutical container, a cutter for cutting the pharmaceuticalcontainer, a rotating unit operable with the gripper unit that rotatesat least a portion of the gripper unit to empty the contents of thepharmaceutical container into a storage container, and at least onedispensing machine that automatically counts and dispensespharmaceuticals from the storage container and into bottles inaccordance with prescription orders comprising at least oneprescription.

The system can also include or utilize at least one printer for printingliterature packs customized to the prescription orders. The system canalso include or utilize at least one order consolidation and packing(OCP) station that presents a shipping container for each prescriptionorder and inserts at least one bottle for each prescription order intothe shipping container and inserts a corresponding literature pack foreach prescription order into the shipping container.

The system can also include a gripper unit for receiving and holding apharmaceutical container, a cutter for cutting the pharmaceuticalcontainer, a rotating unit operable with the gripper unit that rotatesat least a portion of the gripper unit to empty the contents of thepharmaceutical container into a storage container, a plurality ofcarriers, each having receptacles to receive a plurality of bottles inscheduled locations, and at least one dispensing machine that counts andsimultaneously dispenses pharmaceuticals from the pharmaceuticalcontainer and into at least one of the plurality of bottles.

The system can also include or utilize a computer that receivesprescription orders for at least one prescription, as well as a loadingstation that loads the plurality of bottles in the scheduled locationscorresponding to the prescription orders in at least one of saidplurality of carriers.

The system can also include or utilize at least one transport devicethat transports the plurality of carriers with the plurality of bottlesthrough at least one dispensing machine. The system can also include atleast one order consolidation and packing (OCP) station that receivesthe plurality of carriers from the at least one dispensing machine andpresents shipping containers to be filled. The at least one OCP stationunloads the plurality of bottles from the plurality of carriers andloads at least one of the plurality of bottles and a correspondingcustomized literature pack corresponding to a prescription order into ashipping container. The literature pack and each of the bottlesoptionally have at least one corresponding identifier identified by atleast one identification system to ensure that each of one or morebottles associated with the corresponding prescription order areinserted into the shipping container with the corresponding literaturepack.

There has thus been outlined, rather broadly, the features of theinvention in order that the detailed description thereof that followsmay be better understood, and in order that the present contribution tothe art may be better appreciated. There are, of course, additionalfeatures of the invention that will be described hereinafter and whichwill form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of otherembodiments and of being practiced and carried out in various ways.Also, it is to be understood that the phraseology and terminologyemployed herein are for the purpose of description and should not beregarded as limiting.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based, may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe present invention.

These together with other objects of the invention, along with thevarious features of novelty which characterize the invention, arepointed out with particularity in the claims annexed to and forming apart of this disclosure. For a better understanding of the invention,its operating advantages and the specific objects attained by its uses,reference should be had to the accompanying drawings and descriptivematter in which there is illustrated preferred embodiments of theinvention.

Other features of the present invention will be evident to those ofordinary skill, particularly upon consideration of the followingdetailed description of the preferred embodiments.

Notations and Nomenclature

The detailed descriptions which follow may be presented in terms ofprogram procedures executed on computing or processing systems such as,for example, a stand-alone computing machine, a computer or network ofcomputers. These procedural descriptions and representations are themeans used by those skilled in the art to most effectively convey thesubstance of their work to others skilled in the art.

A procedure is here, and generally, conceived to be a sequence of stepsleading to a desired result. These steps are those that may requirephysical manipulations of physical quantities (e.g., combining variouspharmaceutical products into packages). Usually, though not necessarily,these quantities take the form of electrical, optical or magneticsignals capable of being stored, transferred, combined, compared andotherwise manipulated. It proves convenient at times, principally forreasons of common usage, to refer to these signals as bits, values,elements, symbols, characters, terms, numbers, or the like. It should benoted, however, that all of these and similar terms are to be associatedwith the appropriate physical quantities and are merely convenientlabels applied to these quantities.

Further, the manipulations performed are often referred to in terms,such as adding or comparing, which are commonly associated with mentaloperations performed by a human operator. No such capability of a humanoperator is necessary, or desirable in most cases, in any of theoperations described herein which form part of the present invention;the operations are machine operations. Useful machines for performingthe operation of the present invention include general purpose digitalcomputers or similar devices, including, but not limited to,microprocessors.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the present application showing variousdistinctive features may be best understood when the detaileddescription is read in reference to the appended drawings in which:

FIGS. 1A and 1B are exemplary diagrams illustrating a conventionalautomated pill dispenser;

FIG. 2 is an exemplary diagram illustrating a second conventionalautomated pill dispenser;

FIG. 3 is an exemplary diagram illustrating a third conventionalautomated pill dispenser;

FIG. 4A is an exemplary diagram illustrating an embodiment of anautomated pill dispenser in accordance with the present invention;

FIG. 4B is an exemplary diagram illustrating an aspect of an automatedpill dispenser that can be used with the present invention;

FIG. 5 is an exemplary top view of an embodiment of the AutomatedContainer Bulking System (ACBS);

FIGS. 6 a and 6 b, taken together, is an exemplary embodiment of a flowdiagram in accordance with a method of operation of the ACBS;

FIG. 7 is an exemplary embodiment of an infeed conveyor of the ACBS;

FIG. 8 is an exemplary embodiment of a robot of the ACBS;

FIGS. 9 a-9 j are various views of an exemplary embodiment of thegrippers of the ACBS, and bottle positions within the grippers;

FIG. 10 is an exemplary embodiment of a cutter assembly of the ACES;

FIGS. 11 a and 11 b are various perspective views of an exemplaryembodiment of a vacuum assembly of the ACBS;

FIG. 12 a is an exemplary embodiment of a bottle scrap chute of theACBS;

FIG. 12 b is a side view of an exemplary embodiment of a bottle scrapchute of the ACBS in a first position;

FIG. 12 c is a side view of an exemplary embodiment of a bottle scrapchute of the ACES in a second position;

FIG. 12 d is a top view of an exemplary embodiment of a bottle scrapchute of the ACBS in a first position;

FIG. 12 e is top view of an exemplary embodiment of a bottle scrap chuteof the ACBS in a second position

FIG. 13 is an exemplary embodiment of a bottle scrap bin of the ACBS;

FIG. 14 is an exemplary embodiment of a pill accumulation chute of theACBS;

FIG. 15 is an exemplary embodiment of an scanning light beam of theACBS;

FIG. 16 is an exemplary embodiment of a bottle return bin of the ACBS;

FIG. 17 illustrates a computer that can be used in implementingembodiments of the present invention;

FIG. 18 is a block diagram of internal hardware of the examplecomputer/control system shown in FIG. 5;

FIG. 19 illustrates one example of a memory medium which may be used forstoring computer programs of embodiments of the present invention; and

FIG. 20 is a block diagram representation of an example embodiment ofcomputer network(s) implementing embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to the presently preferredembodiments of the invention. Such embodiments are provided by way ofexplanation of the invention, which is not intended to be limitedthereto. In fact, those of ordinary skill in the art may appreciate uponreading the present specification and viewing the present drawings thatvarious modifications and variations can be made.

For example, features illustrated or described as part of one embodimentcan be used on other embodiments to yield a still further embodiment.Additionally, certain features may be interchanged with similar devicesor features not mentioned yet which perform the same or similarfunctions. It is therefore intended that such modifications andvariations are included within the totality of the present invention.

Embodiments of the present invention are directed to dispensing ordersthat include various pharmaceutical products (e.g., bottles that containcounted pills, packages that include liquid or pre-packagedpharmaceutical products and/or patient specific literatures). Inembodiments of the present invention pills also refer to tablets,capsules and other similar terms known in the art. As used herein, theterm pill can also be used interchangeably with, for example, the termstablet and/or capsule.

FIG. 4A is an exemplary diagram illustrating an embodiment of anautomated pill dispensing system 410 in accordance with an embodiment ofthe present invention. In operation, orders (e.g., orders to fillprescriptions) are received by a host computer 9, which forwards theorders to a distributed computer system including a central computercalled Pharmacy Automation Controller 10 (PAC). PAC 10 maintains anorder file of the information about each prescription to be filled in anorder including all of the information needed to fill each prescription,prepare a prescription label for each prescription and the informationto print literature to go in a shipping container with the prescriptionor prescriptions. PAC 10 can update the order file to maintain a recordof the current status of each prescription being filled as it progressesthrough the automated system.

PAC 10 controls a set of Print, Apply and Load (PAL) stations 14 whichprint prescription bottle labels, apply the prescriptions toprescription bottles, and load the labeled bottles onto bottle carriers.PAC 10 also controls a carrier conveyer system 21 which carries thebottle carriers to different parts of the system, automatic drugdispensing machines 23 which dispense tablets or capsules into theprescription bottles in the bottle carriers as they are carried by theconveyer system 21, bottle cappers 25 which apply caps to the bottles,and OCP stations 29 at which the bottles are unloaded from the carriersand placed in the shipping containers corresponding to the patientorders.

An Automated Container Bulking System (ACBS) 450 can also optionallyinterface with PAC 10. As will be described herein with regard to FIGS.5-16, ACBS 450 can be used to empty the contents of, for example,manufacturers' drug bottles shown, e.g., in FIG. 9 at 910, into abulk-up container shown, e.g., in FIGS. 13 and 14 at 1406, that have alarger capacity than individual bottles 910. Using bulk-up containersadvantageously simplifies the number and types of bottles 910 that mustbe used with system 410. ALPS 250 can also optionally be integrated withsystem 410. In addition, a conventional Computer Assisted DispensingSystem (CADS) 460 can optionally be integrated with, for example, ACBS450, ALPS 250 and/or portions of system 410 such as, for example, PAC10.

Conveyer system 21 carries patient prescription bottles in the carriersfrom the PAL stations through the automatic drug dispensing machines 23,to the bottle cappers 25, and then from the bottle cappers to the OCPstations 29. Conveyer system 21 also carries the empty carriers back toPAL stations 14. OCP stations 29 each also have a literature dispensingmechanism, which inserts printed literature into each shipping containerwith the filled and capped prescription bottles. PAC 10 controlsliterature printers 31 which print literature for each prescriptionorder and enclose the literature for each prescription order in anenvelope, print a bar code that shows through a window in the envelopeidentifying the prescription order. PAC 10 can also control placement ofeach envelope on a literature conveyer (not shown), which carries theenvelope from the literature printers 31 to the OCP stations 29.

Patient prescription bottles that are to be automatically filled withthe prescription drugs can be introduced to the automated system byhoppers (not shown, but the same as or similar to hoppers 37 shown inFIG. 1B) which receive the bottles in bulk form and automatically feedthe bottles to unscramblers 39. One hopper 37 and one of theunscramblers (not shown, but the same as or similar to an unscrambler 39shown in FIG. 1B) can be used for relatively large bottles (e.g. 160cc), and the remaining hoppers and unscramblers can be used for smallbottles (e.g., 110 cc). Small bottles preferably an be used for amajority of the prescriptions. Any prescription orders that cannot befilled by using a large bottle can be filled by using multiple largeand/or small bottles. In the unscramblers, the bottles are singulatedand oriented so that the bottle opening first faces downward. Thebottles are then righted and directed to PAL stations 14 on bottleconveyers (not shown, but the same as or similar to conveyors 41, 43shown in FIG. 1B), one for large bottles and one for small bottles.

FIG. 4B is similar to FIG. 1B, and shows exemplary aspects of theautomated pill dispensing system 410 shown in FIG. 4A. In operation, oneor more literature packs can be printed on a printer 31, and sent to acollator 32 for collation into individual literature packs. More thanone collator 32 can optionally be used. Once literature packs arecollated, they can travel, for example, on a standard pinchbelt conveyor33 to a literature pack sorter 35, where they are sorted into literaturepack batches. Although two literature pack sorters 35 are shown, anynumber of literature pack sorters can be utilized to suit, for example,cost and/or volume considerations.

On command from, for example, an OCP station 29, the literature packbatches can optionally be manually transferred from the one or moresorters 35 to a dispatch unit 36. Again, any number of dispatch unitscan be utilized to accommodate, for example, manufacturing, facilitysize and/or cost requirements or constraints. Dispatch units 36 can feedthe literature packs to an OCP station 29.

When system 410 detects (and/or suspects) a problem with an order (e.g.,a wrong shipping address, incorrect prescription drug(s), and/orincorrect prescription quantity), an OCP station 29 can place the orderin a bag, and divert the bag into, for example, a standard tote (notshown). The tote can be transported by, for example, conveyer 101 topackage quality assurance station 96, where a quality assurance personcan inspect the order and correct anything that might be wrong (asdiscussed above) with the order. After inspection and corrective action,the quality assurance person at station 96 can take additional action(s)to ensure that the properly filled order is shipped to thepatient/client.

Operation of ACBS 450 may be best understood with simultaneous referenceto FIG. 5, which depicts a top view of an embodiment of ACBS 450, andFIG. 6, which depicts an embodiment of a flow diagram in accordance witha method of operation of ACBS 450. Reference hereafter will also be madeto FIGS. 7-16, each of which are related to FIGS. 5 and 6.

System 501 automates the process of emptying the contents ofmanufacturers' bottles 910 into a bulk-up container 516 having a largercapacity than individual bottles 910. Bulk-up containers 516, in turn,can be utilized in conjunction with, for example, dispenser for bottles207.

In general, system 501 optionally comprises two (or more) “sides” (e.g.,side 1 and side 2). In FIG. 5, certain components are indicated ashaving “a” and “b” elements (e.g., 901 a and 901 b; 1001 a and 1001 b,etc.). The “a” and “b” elements respectively correspond to sides 1 and 2of system 501. Sides 1 and 2 expedite processing, as well as provide forredundancy in the event that one side is not available (e.g., formaintenance). The present invention also envisions three or more “sides”that can be utilized and provided in an integrated system 501. Anembodiment of system 501 comprising a single side can also be utilized.

System 501 is optionally initialized by verifying user credentials atstep 602. For example, control system 506 can comprise an instructionbanner that optionally displays, for example, Scan and/or Enter EmployeeID for Current Bulk-up Container. Control system 506 can optionallyinclude, for example, a keyboard, personal computer (PC), displaymonitor and/or reader with which an operator can, for example, scanhis/her badge and/or enter his/her password.

In addition, control system 506 can also optionally display, forexample, Scan or Enter National Drug Code (NDC) for a bulk-up container1406 (shown in FIG. 14) that is to be utilized with side 1 or side 2. Inan embodiment, an operator can scan the drug NDC from a bottle 910 byusing barcode scanner 512.

Control system 506 can also optionally display, for example, EnterExpiry Date for NDC. An operator can then enter a valid expiry date,which can be utilized to ensure that (legally) authorized drugs arebeing utilized. If the expiry date falls within a predetermined date ofthe current date (e.g., within six months of the current date), anoverride password (or other override mechanism) can optionally beutilized.

Control system 408 can also optionally display, for example, Enter LotNumber for NDC, whereupon an operator can enter a valid lot number. Uponverifying user credentials and optionally performing other set-upoperations (as described above), an operator can place a bulk-upcontainer 1406 a (and/or 1406 b) in a position so that it respectivelyreceives pills from pill chute 1301. Each side of system 501 preferablyhas its own pill chute 1401 a, 1401 b. Thus, in the embodiment shown inFIG. 5, a first pill chute (1401 a) is utilized for side 1, and a secondpill chute (1401 b) is utilized for side 2.

A multi-colored beacon 504 can optionally be provided, preferably butoptionally in the vicinity of control system 506, to indicate variousstates of system 450. For example, a green beacon can be solid whensystem 450 is in automatic mode, and flash when system 450 is in manualmode (where, e.g., an operator may manually want to control robot 801).An amber beacon can flash when system 450 is low on supplies (e.g.,bottles 910). A red beacon can be solid to indicate that an emergencystop button has been pressed, and/or that a guard door has been opened.A red beacon can flash to indicate that a fault exists (e.g., conveyorbelt 704 is not in operation). Any color scheme can be used. Inaddition, beacon 504 can also include additional color(s) to indicate(or correspond) other states or operating status of system 450 orsub-systems thereof.

The control system 506 PC can utilize software (e.g., Microsoft Access®)to provide and/or access various databases (e.g., one or more drugdatabases, one or more employee databases, one or more end reportdatabases, and the like). In an embodiment, control system 506 PC canalso optionally utilize, for example, a RS-232 connection to interfacewith scanner 512. The PC can read scanner signals, and verify that thedrug is a valid drug as indicated by, for example, one or more the drugdatabases.

In addition, control system 506 PC can optionally utilize, for example,a conventional Ethernet connection to interface with robot 801, visionsystem 518 and/or one or more vacuum valves and/or sensors associatedwith, for example, robot 801. Further, control system 506 PC can alsooptionally utilize the same or a different Ethernet connection tointerface with cutter assembly 1002, conveyor 701 control system and/orvarious vacuum systems that can optionally be utilized to minimize, forexample, pill dust that may be generated when bottles 910 are emptiedand/or when bulk-up containers 1406 are removed.

Control system 506 can also optionally comprise, utilize and/or generatevarious screen displays and/or touch screen menus that allow an operatorto, for example, enter various data and/or control the operation ofsystem 450. For example, system 450 can utilize and/or generate, forexample, run status screen(s) and/or menu(s), manual control screen(s)and/or menu(s), scanner 512 setup screen(s) and/or menu(s), beacon 604status and/or control screen(s) and/or menu(s), alarm history and/orstatus screen(s) and/or menu(s), robot control and/or status screen(s)and/or menu(s), drug data entry screen(s) and/or menu(s), employee dataentry screen(s) and/or menu(s), end report screen(s) and/or menu(s),change operator screen(s) and/or menu(s), employee password screen(s)and/or menu(s), drug expiry date screen(s) and/or menu(s) and/or othervarious system status and/or control screen(s) and/or menu(s).

At step 604, bottles 910 are loaded onto conveyor 701, preferably withthe lids (e.g., a twist cap, not shown) facing up. An exemplaryembodiment of conveyor 701 is shown in FIG. 7. In an embodiment ofsystem 450, a Dorner 800 series flatbelt infeed conveyor (from DornerMfg. Corp., Hartland, Wis.) can be utilized, which includes anilluminated end 702, a belt 704, a gear motor 706, and a support stand708. Conveyor 701 also preferably comprises a control system (not shown)that can optionally interface and/or be integrated with control system506.

Scanner 512 (e.g., a barcode scanner) allows an operator to, forexample, scan a bottle 910 (optionally representative of a batch ofbottles). Scanner 512 can also be used to scan, for example, an operatorID. Scanner 512 can be manufactured by, for example, Datalogic S.p.A.,Bologna, Italy. The bottle barcode (or other identifier) preferably andtypically indicates the drug and bottle type, which allows controlsystem 508 to access any relevant bottle 910 data from, for example, adatabase (as previously discussed).

At step 606, conveyor belt 704 can be used to move one or more bottles910 into view of vision system 518, which is utilized in conjunctionwith robot 801. In particular, vision system 518 can be mounted overheadof robot 801 to view bottles 910. Vision system 518 is preferablypositioned over illuminated conveyor end 702, which facilitates viewing.Illuminated conveyor end 702 is preferably illuminated from below belt704 to assist robot 801 in picking a bottle 910 from conveyor 701. Atstep 608, vision system 518 can relate, for example, position and/ororientation information of one or more bottles 910 to robot 801.

At decision step 612, a determination can be made regarding whethersystem 450 recognizes each bottle 910. Multiple bottle 910 sizes andshapes can be utilized. For example, vision system 518 can optionallyverify that bottles 910 are of the correct diameter and/or overheadshape. If a bottle 910 size and/or shape is not recognized, robot 801will not pick-up the bottle 910, and the bottle 910 can be discarded atstep 610, after which updated bottle 910 position data is provided torobot 801 at step 608. In an embodiment of system 501, bottles 910 thatare not recognized (e.g., wrong bottle, wrong size/shape, bottle fallenover) by vision system 518 are driven off the end of the conveyor 701into bottle return bin 410. An operator can empty bottle return bin 910and reload the proper bottles (e.g., fallen over bottles) 910 ontoconveyor 701.

If, at decision step 612, a bottle 910 is recognized, robot 801 providesthe bottle 910 to a gripper assembly 901 a, 901 b. As previously noted,an embodiment of system 450 comprises two “sides” (e.g., side 1 and side2). If both sides are in operation, system 450 can operate, for example,in a round-robin mode, where robot 801 will alternate each bottle 910between gripper 901 a and 901 b. In the alternative, a single side(e.g., gripper 901 a or gripper 901 b) can be used until the bulk-upcontainer associated with that side is full, and then switch to theother side (which presumably has a bulk-up container that is not full).If, for any reason, only one side of system 450 is being utilized, robot801 will place bottle 910 in the gripper 901 of the side that is beingutilized.

In an embodiment, robot 801 can have or utilize a vacuum in the vicinityof gripper assembly 901 to draw, for example, an end of bottles 910 inclosest proximity to robot 801 to facilitate picking bottles 910 off ofconveyor 701.

At step 614, robot 801 places bottle 910 onto a reciprocating bottleplatform 1204 upon which a surface of bottle 910 rests. Bottle platform1204 is positioned beneath grippers 908 a, 908 b so that bottle 910rests on the platform 1204 prior to grippers 908 a, 908 b gripping thebottle. In a second position, and coincident with or subsequent togripping, bottle platform 1204 is moved away from grippers 908 a, 908 bso that the contents of bottle 910 can subsequently be emptied intobulk-up container 1406 positioned therebelow.

At step 616, rotate mechanism 914 is used to rotate bottle 910 into anupside down orientation (e.g., with the capped end facing down). Vacuumassembly 1101 is positioned near gripper assembly 901 so that suctionplate 1110 can be positioned over the base of the bottle (e.g., thecutting area) when bottle 910 is in the upside down orientation.

At step 618, one of cutter assembly 1001 a, 1001 b is used to cut bottle910. In an embodiment, cutter assembly 1001 a, 1001 b can comprise anultrasonic system (Branson Ultrasonics Corporation, Danbury, Conn.) witha vibrating cutter 1002 that cuts through a bottle. Cutter 1002 a, 1002b can be advanced by pneumatic actuator 522 a, 522 b so that blade 1006cuts bottle 910. In particular, suction plate 1110 holds the bottom of abottle as cutter 1002 a, 1002 b advances. As blade 1006 cuts at or nearan end of a bottle, the cutting action raises the cut portion of thebottle to suction plate 1110, which draws the cut portion of the bottle1112.

After the bottle is cut, rotary actuator 1106 is then actuated to rotaterotary arm 1108 so the bottle scrap 1112 can be placed on one of scrapchute 1201 a, 1201 b (shown in FIG. 5), which feeds the bottle scrap1112 to one of bottle scrap bin 1301 a, 1301 b. Grippers 908 a, 908 bthen rotate bottle 910 approximately 180° so that the contents of bottle910 are emptied onto an accumulation chute 1401 (as shown, e.g., in FIG.14), which leads to a bulk-up container 1406. Vacuum hoods 522 a, 522 bare optionally provided, preferably near cutters 1002 a, 1002 b, tominimize pill dust cross product contamination and/or to control pilldust from spreading. Vacuum capture velocities can be set at, forexample, approximately 100 feet per minute.

Once the contents of the bottle 910 have been emptied, one of scrapchute 1201 a, 1201 b advances to receive the remaining portion of bottle910, which is dropped thereon by one of gripper assembly 901 a, 901 b.One of scrap chute 1201 a, 1201 b retracts and the remaining portion ofbottle 910 is placed into one of scrap bin 1301 a, 1301 b.

When a bulk-up container 1406 is full, an End Report can optionally becreated. An end report can indicate, for example, the drug NDC number,the drug expiry date, the number of pills emptied into a bulk-upcontainer 1406 and/or the time the bulk-up container 1406 stoppedreceiving additional contents from bottles 910. An operator can removebulk-up container 1406, and can choose to run the same drug again orscan a different drug.

In an embodiment, when multiple bulk-up containers 1406 are utilized,the following procedure can be used. When system 450 is processing abulk-up container 406, a NEXT BULK-UP IS SAME NDC pushbutton (or otheractuator) on a Run Status screen can be presented to an operator at, forexample, control system 506. When the pushbutton is pressed, a pop upbox, for example, can be displayed that instructs the operator to scanthe next bulk-up container 1406.

When the current bulk-up container 1406 is finished, a message can bedisplayed that instructs an operator to change bulk-up container 1406.The operator then replaces the existing (full) bulk-up container 1406with the new one.

Preferably near each pill accumulation chute 1401 a, 1401 b a LOAD EMPTYBULK CONTAINER pushbutton (or other actuator) is provided. Thepushbutton can, for example, flash slowly when the current bulk-upcontainer 1406 is full.

Once an operator has placed a new pre scanned-in bulk-up container 1406underneath a pill accumulation chute 1401 a, 1401 b, the correspondingpushbutton can flash rapidly, indicating that the pushbutton should bepressed to acknowledge that a new bulk-up container 1406 has been placedunder a pill accumulation chute 1406 a, 1406 b.

Once an operator has scanned the new bulk-up container 1406 (using,e.g., barcode scanner 512) and has placed it underneath pillaccumulation chute 1401, another pushbutton, for example, can be pushedto continue processing. For example, a LOAD EMPTY BULK CONTAINERpushbutton (of control system 506) can be pushed to continue processingthe existing NDC drug. Of course, actuators other than pushbuttons canalso be utilized.

FIG. 8 is an exemplary embodiment of a robot 801 of the ACES 501. In anembodiment, robot 801 can be an Adept Cobra 600 robot (Adept Technology,Livermore, Calif.) that accommodates x, y, z, and theta movements. Theheight of the bottles is optionally downloaded to control system 506based on the NDC of bottles 910, which can be scanned by barcode scanner512. Robot 801 preferably but optionally has a vacuum end of arm tool(EOAT) that draws the end of the bottle 910 in closest proximity to therobot, and picks the bottle 910 off of the conveyor 701. The EOAT canhandle bottles 910 of varying size and/or diameter. Once a bottle 910has been selected, robot 801 grasps, for example, the cap of a bottle910, optionally rotates the bottle 910 to the correct orientation, andplaces it into one of the two gripper assemblies 901 a, 901 b.

Vision system 518, which is preferably placed over illuminated conveyorend 902, can be used to facilitate viewing bottles 910 and relaying, forexample, location and orientation information of bottles 910 to robot801. Vision system 518 also verifies that the bottles 910 are, forexample, the correct diameter and/or overhead shape. Vision system 518can include a camera available from, for example, PULNiX America,Sunnyvale, Calif.

FIGS. 9 a-9 d show various views of an exemplary embodiment of gripperassembly 901 a, 901 b, which comprises interlocking fingers 908 a, 908 bthat are capable of movement to grip and release bottle 910. In anembodiment, fingers 908 a, 908 b are V-shaped. Rotate mechanism 914 caninclude belt 916, drive pulley 918, and timing belt 920, which allowsgripper assembly 901 a, 901 b to rotate (e.g., 180°) to empty bottle 910contents into a pill accumulation chute 1401 a, 1401 b.

FIGS. 9 e-9 j show two bottle cutting and dispensing scenarios. In FIGS.9 e-9 g, the top of the bottle is cut. In FIG. 9 e, bottle 910 is placedupright in gripper assembly 901 a, 901 b. After the top portion ofbottle 910 is cut, gripper assembly 901 a, 901 b begins to rotate bottle910, as shown in FIG. 9 e. After bottle 910 is rotated approximately180°, as shown in FIG. 9 f, the contents of bottle 910 can be emptiedinto a pill accumulation chute 1401 a, 1401 b. When the bottle is placeduptight in gripper assembly 901 a, 901 b, any cotton can be removed withthe cutting operation. Cotton can also be removed, for example, by a therobot 801 vacuum.

In FIGS. 9 h-9 j, the bottom of the bottle is cut. In FIG. 9 h, bottle910 is placed in gripper assembly 901 a, 901 b with the cap 950 facingdown. After the bottom portion of bottle 910 is cut, gripper assembly901 a, 901 b begins to rotate bottle 910, as shown in FIG. 9 i. Afterbottle 910 is rotated approximately 180°, as shown in FIG. 9 j, thecontents of bottle 910 can be emptied into a pill accumulation chute1401 a, 1401 b.

In an embodiment of the invention, a light beam can optionally be usedto determine whether bottle 910 is held by grippers 908 a, 908 b. Forexample, control system 506 can optionally utilize a reflector 912positioned, for example, on a side wall or portion of gripper 908 b. Inoperation, reflector 912 will not detect light when grippers 908 a, 908b holding a bottle 910. The light beam and reflector 812 can similarlybe used to verify that bottle 910 is released from grippers 908 a, 908 bafter the contents of bottle 910 have been emptied. That is, whenreflector 812 detects light, grippers 908 a, 908 b are not holding abottle 910.

Because some bottles 910 may contain residual glue from the literaturethat was removed from the bottle 910, a non-stick coating can optionallybe added to grippers 908 a, 908 b to facilitate release of a bottle 910.In addition, a continuous stream or intermittent shot of air canoptionally be used in addition to or in lieu of the non-stick coating to“blow” the bottle out of grippers 908 a, 908 b.

Robot 801 loads bottle 910 onto bottle platform 1204, preferably in amanner that accounts for the size and/or shape of the bottle(s) 910. Forexample, oblong and rectangular bottles may be oriented in a certainmanner to allow grippers 908 a, 908 b to properly hold bottle 910. Robot801 retracts and selects another bottle 910. Bottle platform 1204 alsoretracts, and the grippers 908 a, 908 b rotate (e.g., approximately180°) the bottle 910 for cutting. A dust extraction sleeve 904 canoptionally be utilized that draws the dust from the area while bottle910 is cut.

FIGS. 11 a and 11 b show various views of an exemplary embodiment of avacuum assembly 1101, which removes the cut portion of bottle 910 andplaces it into scrap chute 1201. In operation, rotary actuator 1106 isactuated to rotate rotary arm 1108 so that suction plate 1110 is rotatedto (or near) the top of the cutting area (at or near, for example, thebase of bottle 910). As cutter 1002 advances and blade 1006 cuts bottle910, the cutting action raises the cut portion of bottle 910 to thesuction cup 1110. Rotary actuator 1106 then rotates rotary arm 1108 sothat bottle scrap 1112 can be placed into bottle scrap bin 1301.Grippers 908 a, 908 b then rotate bottle 910 so that the contents ofbottle 910 are dumped into pill accumulation chute 1401, as illustratedin FIGS. 9 e-9 j. Vacuum assembly 1101 can also optionally comprise amounting plate 1102 and/or a speed controller 1104 to control the speedof rotation of rotary arm 1108.

FIG. 12 is an exemplary embodiment of scrap chute 1201 a, 1201 b which,after cutting, deflects the remaining portion of emptied bottles 910 andcut off bottle scraps 1112 into scrap bins 1301 (as shown, e.g., in FIG.13). In an embodiment, once the contents of a bottle 910 have beenemptied, chute 1206 (as shown, e.g., in FIG. 12) advances, as shown, forexample, in FIGS. 12 c and 12 e. The advancement of chute 1206 canoptionally be in a position that is substantially transverse withrespect to conveyor belt 704 (as shown, e.g., in FIGS. 5 and 7).Grippers 908 a, 908 b release the remaining portion of bottle 910 ontochute 1206. Chute 1206 retracts, as shown for example in FIGS. 12 b and12 d, and the remaining portion of bottle 1110 slides into scrap bin1301 (FIG. 13). Chute 1206 also can optionally be used to deflect bottlescrap 1112 received from base vacuum assembly 1101 into scrap bin 1301.

Scrap chute 1201 can be mounted to, for example, a Festo rodless aircylinder 1202 (available from Festo Corporation, Hauppauge, N.Y.) whichfacilitates single axis movement. A vacuum hood (not shown) ispreferably provided above each scrap bin 1301 to, for example, minimizepill dust contamination while changing the scrap bin trash bag. vacuumcapture velocities can be, for example, approximately 100 feet perminute. Scrap chute 1201 can also optionally comprise a support angle1208 for mounting.

FIG. 13 shows scrap bin 1301 (positioned near accumulation chute 1401),preferably but optionally having a handle 1308 on each of any twoopposing sides thereof. Sensors (not shown) can be utilized andpositioned to monitor both scrap bin 1301 presence near scrap chute 1201and high level conditions in scrap bin 1301.

In an embodiment of the present invention, a three-position selectorswitch (not shown) is optionally provided to divert the vacuum flow whenchanging either or both of scrap bins 1301 a, 1301 b. When the selectorswitch is set to OFF, the vacuum is diverted, for example, to thecutting area near cutters 1002 a, 1002 b (on both sides), and no vacuumis present at scrap bins 1301 a, 1301 b. When the selector switch is setto side 1, vacuum flow is diverted from the cutting/dumping area toscrap bin 1301 a. Side 1 also optionally becomes disabled so that itdoes not cut any more bottles 910. The same operation preferably occursat side 2 when the selector switch is set to side 2. A curtain 1302 isoptionally provided to help isolate any dust inside bin housing area1304.

FIG. 14 is an exemplary embodiment of a pill accumulation chute 1401.The contents of bottle 910 (e.g., pills) are emptied into funnel 1402that directs the pills into bulk-up container 1406. Manifold 1404connects bulk-up container 1406 to funnel 1402, and can optionallyinclude a vacuum to absorb any pill dust that may emanate from placingthe pills in bulk-up container 1406. Vacuum capture velocities can be,for example, approximately 20 feet per minute. A support bar 1408 canalso optionally be provided. Top chute 1410 and deflector 1412 can alsooptionally be provided to guide bottle 910 contents.

Referring to FIG. 15, a light beam unit (e.g., a Banner A-Gage™Mini-Array™ unit) 1501 is shown that can be positioned, for example, onopposing sides of accumulation chute 1401 to verify that product didindeed empty out of bottle 910 and onto pill collection chute 1401.Light beam unit 1501 is preferably but optionally integrated withcontrol system 506. Light beam units 1501 can include a light emitter1406 and receiver 1404. Light emitter 1406 sends, for example, a seriesof light beams to receiver 1404. As bottle 910 product falls ontoaccumulation chute 1401, it breaks the light beam, thus providing asignal indicating that product is still being dispensed. As bottle 910product stops falling onto accumulation chute 1401, the light beam isunbroken, thereby providing a signal indicating that product is notbeing dispensed.

FIG. 16 is an exemplary embodiment of a bottle return bin 1601. Bottlereturn bin 1601 receives unopened manufacturer bottles that were notpicked by robot 801. Any bottles 910 that, for example, are notrecognized by vision system 518 (e.g., wrong bottle, fallen over) aredriven off conveyor belt 702 and onto bottle return chute 514, whichtransports bottles 910 into bottle return bin 1601. A retroreflectivesensor, for example, can optionally be utilized to detect that the bin1601 is both full and present.

Viewed externally in FIG. 17, a computer system (e.g., the host computer201 or the local computers) designated by reference numeral 1740 has acomputer 1742 having disk drives 1744 and 1746. Disk drive indications1744 and 1746 are merely symbolic of a number of disk drives which mightbe accommodated by the computer system. Typically, these would include afloppy disk drive 1744, a hard disk drive (not shown externally) and aCD ROM indicated by slot 1746. The number and type of drives vary,typically with different computer configurations. Disk drives 1744 and1746 are in fact optional, and for space considerations, are easilyomitted from the computer system used in conjunction with the productionprocess/apparatus described herein.

The computer system also has an optional display 1718 upon whichinformation screens may be displayed. In some situations, a keyboard1750 and a mouse 1752 are provided as input devices through which auser's actions may be inputted, thus allowing input to interface withthe central processing unit 1742. Then again, for enhanced portability,the keyboard 1750 is either a limited function keyboard or omitted inits entirety. In addition, mouse 1752 optionally is a touch pad controldevice, or a track ball device, or even omitted in its entirety as well,and similarly may be used to input a user's selections. In addition, thecomputer system also optionally includes at least one infraredtransmitter and/or infrared received for either transmitting and/orreceiving infrared signals, as described below.

FIG. 18 illustrates a block diagram of one example of the internalhardware 1840 configured to perform various example steps as describedabove. A bus 1856 serves as the main information highway interconnectingvarious components therein. CPU 1858 is the central processing unit ofthe internal hardware 1840, performing calculations and logic operationsrequired to execute the control/operation processes of the presentinvention as well as other programs. Read only memory (ROM) 1860 andrandom access memory (RAM) 1862 constitute the main memory of theinternal hardware 1840. Disk controller 1864 interfaces one or more diskdrives to the system bus 1856. These disk drives are, for example,floppy disk drives 1744, or CD ROM or DVD (digital video disks) drives1746, or internal or external hard drives 1868. These various diskdrives and disk controllers are optional devices.

A display interface 1872 interfaces display 1748 and permits informationfrom the bus 1856 to be displayed on display 1748. Communications withexternal devices such as the other components (e.g., a PLC) of thesystem described above, occur utilizing, for example, communication port1874. Optical fibers and/or electrical cables and/or conductors and/oroptical communication (e.g., infrared, and the like) and/or wirelesscommunication (e.g., radio frequency (RF), and the like) can be used asthe transport medium between the external devices and communication port1874. Peripheral interface 1854 interfaces the keyboard 1750 and mouse1752, permitting input data to be transmitted to bus 1856. In additionto these components, the internal hardware 1840 also optionally includean infrared transmitter and/or infrared receiver. Infrared transmittersare optionally utilized when the computer system is used in conjunctionwith one or more of the processing components/stations/modules thattransmits/receives data via infrared signal transmission. Instead ofutilizing an infrared transmitter or infrared receiver, the computersystem may also optionally use a low power radio transmitter 1876 and/ora low power radio receiver 1878. The low power radio transmittertransmits the signal for reception by components of the productionprocess, and receives signals from the components via the low powerradio receiver. The low power radio transmitter and/or receiver arestandard devices in industry.

Although the server in FIG. 18 is illustrated having a single processor1858, a single hard disk drive 1868 and a single local memory 1862, theinternal hardware 1840 is optionally suitably equipped with anymultitude or combination of processors or storage devices. For example,the computer 1742 may be replaced by, or combined with, any suitableprocessing system operative in accordance with the principles ofembodiments of the present invention, including sophisticatedcalculators, and hand-held, laptop/notebook, mini, mainframe and supercomputers, as well as processing system network combinations of thesame.

FIG. 19 is, an illustration of an example computer readable memorymedium 1984 utilizable for storing computer readable code orinstructions. As one example; medium 1984 may be used with disk drivesillustrated in FIG. 18. Typically, memory media such as floppy disks, ora CD ROM, or a digital video disk will contain, for example, amulti-byte locale for a single byte language and the program informationfor controlling system 410 and/or 450 to enable, for example, controlsystem 506 to perform the functions described herein. Alternatively, ROM1860 and/or RAM 1862 illustrated in FIG. 18 can also be used to storethe program information that is used to instruct CPU 1858 to perform theoperations associated with various automated processes of the presentinvention. Other examples of suitable computer readable media forstoring information include magnetic, electronic, or optical (includingholographic) storage, some combination thereof, etc.

FIG. 20 is an illustration of the architecture of the combined Internet,POTS (plain, old, telephone service), and ADSL (asymmetric, digital,subscriber line) for use in accordance with the principles of thepresent invention. In other words, instead of using dedicated lines andsuch communication schemes associated with, for example, control system506, this example embodiment envisions a remotely controllable system.Furthermore, it is to be understood that the use of the Internet, ADSL,and POTS are for exemplary reasons only and that any suitablecommunications network may be substituted without departing from theprinciples of the present invention. This particular example is brieflydiscussed below.

In FIG. 20, to preserve POTS and to prevent a fault in the ADSLequipment 2054, 2056 from compromising analog voice traffic 2026 thevoice part of the spectrum (the lowest 4 kHz) is separated from the restby a passive filter, called a POTS splitter 2058, 2060. The rest of theavailable bandwidth—from about 10 kHz to 1 MHz—carries data at, forexample, rates up to 6 bits per second for every hertz of bandwidth fromdata equipment 2062, 2064, and 2094. The ADSL equipment 2056 then hasaccess to a number of destinations including, for example, the Internet2020 or other data communications networks, and other destinations 2070.

To exploit the higher frequencies, ADSL makes use of advanced modulationtechniques, of which the best known is the discrete multitone (DMT)technology. As its name implies, ADSL transmits data asymmetrically—atdifferent rates upstream toward the central office 2052 and downstreamtoward systems 410 and/or 450.

Cable modems come in many forms. Most create a downstream data streamout of one of the 6-MHz TV channels that occupy spectrum above 50 MHz(and more likely 550 MHz) and carve an, upstream channel out of the5-50-MHz band, which is currently unused. Using 64-state quadratureamplitude modulation (64 QAM), a downstream channel can realisticallytransmit about 30 Mb/s (the oft-quoted lower speed of 10 Mb/s refers toPC rates associated with Ethernet connections). Upstream rates differconsiderably from vendor to vendor, but good hybrid fiber/coax systemscan deliver upstream speeds of a few megabits per second. Thus, likeADSL, cable modems transmit much more information downstream thanupstream. Then Internet architecture 2020 and ADSL architecture 2054,2056 may also be combined with, for example, other networks 2022, 2024,and 2028.

In accordance with the principles of the present invention, in oneexample, a main computing server (e.g., in one embodiment, controlsystem 506) implementing the process of the invention may be located onone or more computing nodes or terminals (e.g., on networks 2022, 2024and/or 2028. Then, various users (e.g., one or more of the localcomputers described above) may interface with the main server via, forinstance, the ADSL equipment discussed above, and access the informationand processes of the present invention from remotely located PCs.Database 2086 is accessible via, for example, control system 506.

In general, it should be emphasized that the various components ofembodiments of the present invention can be implemented in hardware,software or a combination thereof. In such embodiments, the variouscomponents and steps would be implemented in hardware and/or software toperform the functions of embodiments of the present invention. Anypresently available or future developed computer software languageand/or hardware components can be employed in such embodiments of thepresent invention. For example, at least some of the functionalitymentioned above could be implemented using Visual Basic, C, C++, or anyassembly language appropriate in view of the processor(s) being used. Itcould also be written in an interpretive environment such as Java andtransported to multiple destinations to various users.

The many features and advantages of embodiments of the present inventionare apparent from the detailed specification, and thus, it is intendedby the appended claims to cover all such features and advantages of theinvention which fall within the true spirit and scope of the invention.Further, since numerous modifications and variations will readily occurto those skilled in the art, it is not desired to limit the invention tothe exact construction and operation illustrated and described, andaccordingly, all suitable modifications and equivalents may be resortedto, falling within the scope of the invention.

1-18. (canceled)
 19. A method comprising: holding a pharmaceuticalcontainer with a gripper unit; cutting the pharmaceutical container witha cutter; and rotating the pharmaceutical container with a rotating unitoperable with the gripper unit to empty contents of the pharmaceuticalcontainer into a bulk container after the pharmaceutical container iscut.
 20. The method of claim 19, further comprising: rotating thepharmaceutical container to a first position to receive a cut portion ofthe pharmaceutical container, and rotating to a second position to placethe cut portion in a waste repository.
 21. The method of claim 20,further comprising: utilizing a vacuum to retain the cut portion of thepharmaceutical container when the rotating unit is in the firstposition, and decreasing the vacuum when the rotating unit is in thesecond position to effect release of the cut portion.
 22. The method ofclaim 19, further comprising: receiving a portion of the pharmaceuticalcontainer subsequent to emptying the contents of the pharmaceuticalcontainer using a scrap chute.
 23. The method of claim 22, furthercomprising: moving to a proximal position with respect to the gripperunit to receive a portion of the pharmaceutical container held by thegripper unit subsequent to emptying the contents of the pharmaceuticalcontainer when the scrap chute is in a distal position with respect tothe gripper unit prior to emptying the contents of the pharmaceuticalcontainer, and returning the scrap chute to the distal position to placethe portion of the pharmaceutical container held by the gripper unit ina scrap bin.
 24. The method of claim 19, further comprising: determiningwhen the contents are no longer being emptied directly from thepharmaceutical container using a sensor unit.
 25. The method of claim24, further comprising: detecting when the pharmaceutical container isno longer being held by said gripper unit using a detection system. 26.The method of claim 25, further comprising: detecting when thepharmaceutical container is being held by the gripper unit when lightfrom a light beam source is not reflected.
 27. The method of claim 26,further comprising: determining whether pharmaceuticals are authorizedby a control unit when indicia associated with the pharmaceuticalcontainer is read by an indicia reader.
 28. The method of claim 19,further comprising: receiving identification information of a systemoperator by a control unit.
 29. The method of claim 19, furthercomprising: verifying that the pharmaceutical container is the correctdiameter, has the correct overhead shape, or both is the correctdiameter and has the correct overhead shape using a vision unit.
 30. Themethod of claim 19, further comprising: placing the pharmaceuticalcontainer in the gripper unit, and removing cotton with at least acutting operation, a robot vacuum, or both a cutting operation and arobot vacuum.
 31. The method of claim 19, further comprising: verifyingthat the contents emptied directly from the pharmaceutical containerusing a light beam unit.
 32. The method of claim 19, further comprising:viewing the pharmaceutical container using an electronic viewer beforeholding and cutting the pharmaceutical container for providingpositioning information of the pharmaceutical container.
 33. The methodof claim 19, further comprising: providing a vacuum flow in the area ofthe cutter.
 34. The method of claim 19, further comprising: transportingthe pharmaceutical container; determining information provided on thepharmaceutical container to identifying the pharmaceuticals containedtherein; and determining whether the pharmaceuticals are authorized tobe emptied from the pharmaceutical container into a bulk containerresponsive to the determined information, wherein the pharmaceuticalcontainer is held with the gripper unit when a determination is madethat the pharmaceuticals are authorized to be emptied.
 35. The method ofclaim 19, further comprising: determining an orientation of thepharmaceutical container; orientating the pharmaceutical containerresponsive to the determined orientation, wherein the cutting of thepharmaceutical container is performed in response to orientation of thepharmaceutical container.
 36. The method of claim 19, wherein cuttingpharmaceutical container comprises: cutting the pharmaceutical containeron a sidewall of the of the pharmaceutical container, a bottom of thepharmaceutical container, or both the sidewall and the bottom of thepharmaceutical container.
 37. The method of claim 19, furthercomprising: determining when the contents of the pharmaceuticalcontainer are no longer being emptied into the bulk container;controlling cutting and rotating of the pharmaceutical container toempty the contents into the bulk container; and periodically emptyingbulk container contents of the bulk container into an automatedpharmaceutical dispensing system for subsequent automated dispensing ofthe pharmaceutical in into an additional pharmaceutical containerresponsive to a patient specific prescription order.